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Additive Manufacturing (3D-printing) of Spare Parts For Industrial Gas Turbines
Additive Manufacturing (3D-printing) of spare parts for industrial gas turbines

With the additive manufacturing (AM) technology of selective laser melting (SLM), Siemens can repair parts for your industrial gas turbines up to ten times faster and with full freedom of design possibilities. Within the last years, additive manufacturing has emerged and is revolutionizing the manufacturing of components. This technology allows design improvement and rapid manufacturing of components, thus enabling quick upgrading of existing assets to the latest part design.

Advantages of Additive Manufacturing for Servicing Gas Turbines
  •     90% lead time reduction
  •     Up to 60% fuel (natural gas) reduction possible by our advanced nozzle designs in case of H2 utilization
  •     Up to 50% emissions reductions achievable
  •     Require up to 65% less electrical power, compared to conventional manufacturing
  •     Increasing performance by upgrading spares to the newest design
  •     Increased efficiency through unlimited options for internal and external cooling duct design:
    - Better heat transfer and lattice structures
    - No restrictions of geometry in design
    - Increased coating adhesion
  •     Improved lifetime of components by using new powder alloys
Areas of application

AM is a revolutionary technology enabling both components performance enhancement and delivery time reduction simultaneously.

At Siemens we are using AM (SLM) technology for three main applications:
  • rapid prototyping
  • rapid repair and
  • rapid manufacturing.

Rapid prototyping

Prototypes are increasingly being used during product development to test certain properties before series production begins.
In the past, due to long delivery of new components manufactured by conventional methods (e.g. casting), component validation testing was done almost at the end of the development process.

With AM as an integral part of the development process, components design and manufacturing are realized and tested during the development achieving fast development cycles.
For example, utilization of AM technology for Compressor Turbine blade design enables the evaluation a few blade cooling concepts and their tests in a real engine environment in a few months instead of a few years.

Additive manufacturing enables both components delivery time reduction as well as performance enhancement.

With selected laser melting, complex multi-elements components can be produced as just one integral part achieving high precision in production and, in most cases, an increased performance.

Rapid Repair

The repair procedures for SGT-700 and SGT -800 burners tips using SLM technology is 10 times quicker than previously used ‘conventional’ repair procedures. This procedure consists of:

Replacement of conventional repair processes with selective laser melting (SLM) provided not only a significant reduction in repair time, but also an opportunity to modify repaired components to the latest burner design.

Rapid Manufacturing

AM technology industrialization is also enabling new opportunities for spare part and supply chain enhancement such as the manufacturing of spare parts on demand and even on site, regionalization of rapid repair and manufacturing of GT components.

Currently, Siemens uses SLM for rapid repair and manufacturing of Siemens Gas turbine components.
source: http://www.energy.siemens.com/hq/en/services/industrial-applications/additive-manufacturing.htm
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